Honda TRX400FW Foreman 400, TRX450S/FM, TRX450ES/FE Foreman 450, TRX500FA/FGA Foreman Rubicon 500 Repair Manual 1995-2007

• Honda TRX400FW Foreman 400, 1995-2003
• Honda TRX450S/FM, 1998-2004
• Honda TRX450ES/FE Foreman 450, 1998-2004
• Honda TRX500FA/FGA Foreman Rubicon 500, 2001-2007

The engine/transmission unit is of the air-cooled, single-cylinder four-stroke design. The two valves are operated by pushrods and solid lifters.

The lifters are operated by a camshaft mounted in the crankcase, which in turn is chain driven off the crankshaft.

The engine/transmission assembly is constructed from aluminum alloy. The crankcase is divided vertically.

The crankshaft centerline is parallel to the centerline of the vehicle.

The crankcase incorporates a wet sump, pressure-fed lubrication system which uses a gear-driven rotor-type oil pump, an oil filter and separate strainer screen and an oil temperature warning switch.

Power from the crankshaft is routed to the transmission via two clutches. The centrifugal clutch, which engages as engine speed is increased, connects the crankshaft to the change clutch, which is of the wet, multi-plate type.

The change clutch transmits power to the transmission; it's engaged and disengaged automatically when the shift lever is moved from one gear position to another.

The transmission has five forward gears and one reverse gear.

• Maintenance
• Engine, clutch and transmission
• Fuel system and lubrication
• Ignition system
• Frame and forks
• Wheels, brakes and tires
• Electrical system
• Wiring diagrams